This is part ten of a series of posts on this highly custom 1938 Chevrolet Truck classic restoration, in post one we introduce you to the project and the custom features to be fabricated.  In post two of classic restoration, we look at the individual truck parts that make up the front end build In post three of classic restoration, we cover the chassis build and drip rail removal In post four of classic restoration, we show you the process of metal finishing the fenders. Post five of classic restoration takes us through the panel restoration of the original inner grille housing panel and a custom touch of deleting the cowl vent panel.  Post six of classic restoration takes care of the lower cowl metal and left hand front fender.  Post seven of classic restoration covers the toe board panel, door lock upgrades, and mainly the upgrades to the inner fender support panel; this panel has to be heavily modified to take the new location of the hood side panels. Post eight of classic restoration looks at how the custom hood was created to open by pulling forward instead of the original butterfly design.

This post will show the original firewall modifications, mainly by lowering the distributor depression, and then filling in the void above with an aluminum close out panel, that will be bonded to the original firewall.

The close out panel fabrication involves using the Baileigh bead roller to create raised areas to give a factory Chevrolet look.

The final set of photos show the cowl bead build process, to correct poor metal structure from the original one, to round out the metal work on the front of the Chevrolet cab.

Classic Restoration: Firewall panel fabrication

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Original firewall face.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Since this build will have a modern 350 Chevrolet engine, we can lower the firewall depression.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Welded in and metal finished.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

To make the firewall more interesting we made a close out panel. Here’s the beginning of making the template.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Tracing the template to the aluminum sheet.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Sheet metal perimeter cut out and offered up to the firewall.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Bead work in progress with our Baileigh equipment.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Close up of bead work.

Classic Restoration: Completed firewall panel

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

 

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Classic Restoration: Cowl Metal Work

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Previous cowl top was damaged and weak from the media blasters so we made a new section to graft in.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Profile/ side view from hood to style line.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Grafting in and TIG welding stage.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Onto the metal finishing stage.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Close up profile view of the finished product.

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Classic Restoration of Chevrolet 1938 Truck Part 10 at The Metal Surgeon

Finally, the overview of the completed cowl.

This is part ten of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated.  In post two, we look at the individual truck parts that make up the front end build In post three, we cover the chassis build and drip rail removal In post four, we show you the process of metal finishing the fenders. Post five takes us through the panel restoration of the original inner grille housing panel and a custom touch of deleting the cowl vent panel.  Post six takes care of the lower cowl metal and left hand front fender.  Post seven covers the toe board panel, door lock upgrades, and mainly the upgrades to the inner fender support panel; this panel has to be heavily modified to take the new location of the hood side panels.  Post eight looks at how the custom hood was created to open by pulling forward instead of the original butterfly design.

One Response

  1. Creating a repair panel for a 1938 Chevy Truck Grille Shell | THE METAL SURGEON

    […] This is part eleven of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated.  In post two, we look at the individual truck parts that make up the front end build.  In post three, we cover the chassis build and drip rail removal.  In post four, we show you the process of metal finishing the fenders. Post five takes us through the panel restoration of the original inner grille housing panel and a custom touch of deleting the cowl vent panel.  Post six takes care of the lower cowl metal and left hand front fender.  Post seven covers the toe board panel, door lock upgrades, and mainly the upgrades to the inner fender support panel; this panel has to be heavily modified to take the new location of the hood side panels.  Post eight looks at how the custom hood was created to open by pulling forward instead of the original butterfly design.  Post nine covers the rest of the custom hood, which involves completion of the skin, and design and fabrication of the inner structure.  Post ten shows the firewall modifications. […]

    Reply

Leave a Reply

Your email address will not be published.

This site is protected by Comment SPAM Wiper.